Microstructure development in latex coatings: High-resolution cryo-scanning electron microscopy

High-resolution cryogenic scanning electron microscopy (Cryo-SEM) was used to investigate microstructure development in drying latex coatings: from a colloidal stable suspension into a coherent strong film by drying. Useful sample preparation artifacts during the freeze-fracture, i.e., pullouts were documented and analyzed. Pullouts indicate both physical properties of latex particles and the drying stages in latex coatings. The mechanism of pullout formation was studied both theoretically and experimentally.; Latex coatings must possess satisfactory freeze-thaw stability to avoid problems during transportation and storage in cold winter. The behavior of latex particles during freeze-thaw cycles was visualized by Cryo-SEM. The images indicated that high concentration of polymerizable surfactant in a latex suspension improved its freeze-thaw stability.; In film formation, skinning was captured from edge in and top down in coatings of 80nm diameter styrene-butadiene latex particles with exceptional low Tg (-65°C). Effects on skinning of drying conditions and the way the latex was initially stabilized against flocculation were investigated. A skinned pocket was unexpectedly found in the coating. The cause of such a skin around the air bubble was explained by both simple models calculating the dissolution time and force analysis on the particles. The film formation processes in conventional and low volatile organic compound (VOC) latex coatings were compared by time-sectioning Cryo-SEM. Some low-VOC latex coatings were found to dry as fast as conventional ones without deteriorating final good film properties.